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D60 carrier removal........HELP!!!!!!!!!!111

Discussion in 'The Garage' started by 6.2Blazer, Nov 9, 2004.

  1. 6.2Blazer

    6.2Blazer 1/2 ton status

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    Okay, I'm just about out of patience with this thing.

    Background:
    I broke the shortside (passenger) inner axleshaft on my front Dana 60 on my last trailride (it was an older "necked-down" shaft). This in turn wiped out the inner axle seal.

    I've had these axles apart before, and I completely stripped and rebuilt this one before installing it into my truck including removing the carrier several times while setting up the gears and always just used a couple of prybars.

    However, I cannot for the life of me get the frickin' carrier out now. I've tried:

    case spreader
    multiple prybars up to 3' long in multiple positions
    slide hammer
    large deadblow hammer
    extra person
    and every combination of the above (case spreader installed, one person prying on it with two bars, and me using a slide hammer)

    I can get the passenger side started (the side the shaft broke on), but cannot budge the drivers side.

    It's an open 4.10 carrier with a Lock-right. There is no sign of locker damage and no chunks fell out of the gear lube. The carrier has some scarring from a previous pinion bearing failure (prior to me getting and rebuilding the axle). There was some water in the diff from having to go through some creeks after the shaft broke. There is nothing obvious stuck in the axle tubes that I can see.

    The bearing caps are removed and both side axleshafts are removed...........anybody have any ideas????? /forums/images/graemlins/dunno.gif

    I'm literally almost ready to torch the carrier in half /forums/images/graemlins/eek.gif
     
  2. 84_Chevy_K10

    84_Chevy_K10 Banned

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    Turn the pinion, it'll push the carrier out.
     
  3. 6.2Blazer

    6.2Blazer 1/2 ton status

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    [ QUOTE ]
    Turn the pinion, it'll push the carrier out.

    [/ QUOTE ]

    I suppose if you had some resistance to keep the carrier from rotating, but with the axleshafts out you can spin the pinion all day long and it just spins the carrier..............
     
  4. Fubeca

    Fubeca 1/2 ton status

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    Put a wrench on one of the ring gear bolts so it will hit the housing as the carrier rotates. Then turn the pinion and it will force itself out.
     
  5. K5MONSTERCHEV

    K5MONSTERCHEV 1/2 ton status

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    [ QUOTE ]

    multiple prybars up to 3' long in multiple positions


    [/ QUOTE ]

    Theres your problem. Get bigger pry bars. Thats all I ever use at work, 2 big pry bars.
     
  6. surpip

    surpip 1 ton status

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  7. JK5

    JK5 1/2 ton status GMOTM Winner

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    Is the inner shaft..still stuck in the carrier???
    If it is...that may be your problem.
     
  8. Ryan B.

    Ryan B. 3/4 ton status GMOTM Winner

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    you beat me to it... sirpimp. /forums/images/graemlins/pimp1.gif /forums/images/graemlins/k5.gif /forums/images/graemlins/cool.gif

    /forums/images/graemlins/thumb.gif /forums/images/graemlins/k5.gif
     
  9. 6.2Blazer

    6.2Blazer 1/2 ton status

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    Both side shafts are completely removed........to get the broken piece out I had to pull the other side shaft and center pin out, and then run a long pipe all the way through the axle from one side to the other. The splined part of the broken shaft came out of the side gears on the locker easily. You can look down one axle tube and see out the other side.
     
  10. JK5

    JK5 1/2 ton status GMOTM Winner

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    ok...I just had to ask..

    I'd try Ryan B's method..
     
  11. Ryan B.

    Ryan B. 3/4 ton status GMOTM Winner

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    /forums/images/graemlins/thumb.gif /forums/images/graemlins/k5.gif


    Yep. No case spreader needed.. This method is cake. ->
    3/4" box wrench on a ring gear bolt.
    Turn it over till it wedges the wrench against the bottom of the housing.
    Get a socket or big ass crescent wrench on the pinion nut.. Give it some more leverage and the gear mesh will walk the carrier out of the housing. Make sure someone is there to catch it, or some pillows or something.. /forums/images/graemlins/thumb.gif /forums/images/graemlins/deal.gif
     
  12. az-k5

    az-k5 1/2 ton status

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    That is the way I do it. You don't even have to remove the d-shaft, just slide a pry bar in beween the yokes and u-joint and turn it. I wish every centersection was like a 14FF though. Those are about as easy as puttin on a tire.
     
  13. 6.2Blazer

    6.2Blazer 1/2 ton status

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    [ QUOTE ]
    I wish every centersection was like a 14FF though. Those are about as easy as puttin on a tire.

    [/ QUOTE ]

    I'm with you on that one!
     

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